Surface coal mining activities keep on increasing with the rising demand for power. In addition to opening of new mines, often existing surface mines are being expanded to cater to the growing coal production. Successful surface coal mine requires large size haul trucks. Large haul trucks need better haul roads. A stable road base is one of the most important components of haul road design. Haul road is a multi-layered structure that consists of four layers as surface, base, subbase and subgrade. Mine haul roads provide the principal means of material transport on surface strip coal mines. Design and management of these roads is based primarily on local experience and adopted empirical guidelines. Mine haul roads are typically constructed by using locally available materials, the overburden materials being the principal source. Common construction material for haul road as sand, gravels, clay, etc. result only in filling the spaces instead of offering total solution to ground stability. Conventionally the mines use an empirical design method that presents inadequate design. With increasing truck size, these pavement design and management systems exhibit poor performance of haul road. The maintenance costs of existing roads not only increase but also vehicle operating and maintenance costs increase prohibitively. The behaviour of the surface course of haul road depends on the bearing capacity of the materials that are lying beneath it. Proposed investigation is an attempt to evaluate the existing construction material as well as develop alternate material for large size haul roads. The investigation proposes to evaluate locally available material as well as fly ash and/or parting material between seams that are typically available at zero cost for the same. These days usage of geotextiles has improved the performance of pavement in many ways, specifically in enhancing tensile strength to prevent failure of the road. Polypropylene is a type of geotextile that has gained popularity in paved construction. The influence of same in unpaved road i.e. haul road has not been evaluated. Investigation would form an experimentally developed material and optimize the same in haul road design through numerical modeling